Composite with thermo-formability, method for making the same and method for making a casing with texture on surface thereof

ABSTRACT

The present invention relates to a composite with thermo-formability, a method for making the same and a method for making a casing with a texture on the surface thereof. The composite includes a PU medium layer, a thermo-formable resin layer, a base layer and a surface layer. The thermo-formable resin layer is disposed on the PU medium layer, and includes polyol. The base layer is disposed on the thermo-formable resin layer. The surface layer is disposed on the base layer. As a result, the composite has good stability after thermoforming, and plastic can be injected into the composite, so a PC film is unnecessary. Moreover, the composite may be adhered to a substrate directly or after thermoforming.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a composite, a method for making the same and a method for making a casing, and more particularly to a composite with thermo-formability, a method for making the same and a method for making a casing with a texture on the surface thereof.

2. Description of the Related Art

FIG. 1 shows a cross-sectional view of a conventional composite. The conventional composite 1 includes a PC film 15, a second adhesive layer 14, a PU wet foamed layer 13, a first adhesive layer 12 and a surface layer 11. The material of the PC film 15 is thermoplastic. The second adhesive layer 14 is disposed on the PC film 15. The PU wet foamed layer 13 is disposed on the second adhesive layer 14. The first adhesive layer 12 is disposed on the PU wet foamed layer 13. The surface layer 11 is disposed on the first adhesive layer 12, the material of the surface layer 11 is PU resin, and the surface layer 11 has a texture. The conventional composite 1 is attached to a substrate, which is usually a casing of an electrical device (for example, a notebook, PDA, mobile phone or LCD). After heat pressing, the conventional composite 1 is attached to the casing by the PC film 15. In such a manner, the texture of the surface layer 11 and the artificial leather of the conventional composite 1 can improve the tactile quality of the electrical device.

The conventional composite 1 has the following disadvantage. The PC film 15 easily peels off or warps after thermoforming, and has poor formability, which leads to difficulty in the following processes, and further leads to a low yield rate.

Therefore, it is necessary to provide a composite with thermo-formability, a method for making the same and a method for making a casing with a texture on the surface thereof to solve the above problems.

SUMMARY OF THE INVENTION

The present invention is directed to a method for making a composite with thermo-formability. The method comprises the following steps: (a) providing a release paper; (b) forming a surface layer on the release paper; (c) forming a base layer on the surface layer; (d) forming a thermo-formable resin layer that includes polyol on the base layer; (e) forming a PU medium layer on the thermo-formable resin layer; and (f) removing the release paper.

The present invention is further directed to a composite with thermo-formability. The composite includes a PU medium layer, a thermo-formable resin layer, a base layer and a surface layer. The thermo-formable resin layer is disposed on the PU medium layer, and includes polyol. The base layer is disposed on the thermo-formable resin layer. The surface layer is disposed on the base layer.

The present invention is further directed to a method for making a casing with a texture on the surface thereof. The method comprises the following steps: (a) providing a composite that includes a PU medium layer, a thermo-formable resin layer, a base layer and a surface layer; the thermo-formable resin layer includes polyol and is disposed on the PU medium layer, the base layer is disposed on the thermo-formable resin layer, the surface layer is disposed on the base layer, and the surface layer has a texture on the surface thereof; (b) thermoforming the composite into a 3D appearance by a mold; (c) providing a casing; and (d) adhering the composite to the casing.

The present invention is further directed to a method for making a casing with a texture on the surface thereof. The method comprises the following steps: (a) providing a composite that includes a PU medium layer, a thermo-formable resin layer, a base layer and a surface layer; the thermo-formable resin layer includes polyol and is disposed on the PU medium layer, the base layer is disposed on the thermo-formable resin layer, the surface layer is disposed on the base layer, and the surface layer has a texture on the surface thereof; (b) thermoforming the composite into a 3D appearance by a mold; the composite has an inner surface and an outer surface, and the inner surface defines an inner space; and (c) forming plastic on the inner surface of the inner space by injection molding so as to form a casing.

As a result, the composite has good stability after thermoforming and the PC film will not peel off as in the conventional composite. In addition, the plastic can be injected into the composite, so the conventional PC film is unnecessary. Moreover, the composite of the present invention can be adhered to a substrate directly or after thermoforming.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is the cross-sectional view of the conventional composite;

FIGS. 2 to 8 are cross-sectional views of a method for making a composite with thermo-formability according to a first embodiment of the present invention;

FIGS. 9 to 14 are cross-sectional views of a method for making a composite with thermo-formability according to a second embodiment of the present invention;

FIGS. 15 to 17 are cross-sectional views of a method for making a casing with a texture on the surface thereof according to the first embodiment of the present invention; and

FIGS. 18 to 20 are cross-sectional views of a method for making a composite with thermo-formability according to the second embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 2 to 8 show the cross-sectional views of the method for making a composite with thermo-formability according to the first embodiment of the present invention. First, referring to FIG. 2, a release paper 21 is provided. In the embodiment, the surface of the release paper 21 has a texture. Then, referring to FIG. 3, a surface layer 22 is formed on the release paper 21. In the embodiment, the surface layer 22 is formed by coating, and includes a PU resin, resistant and colorant. The resistant includes silicon so that the abrasion resistance is increased, and the colorant increases the UV resistance and the solvent resistance. In the embodiment, the method further comprises a step of drying the surface layer 22. Then, a base layer 23 (FIG. 5) is formed on the surface layer 22. In the embodiment, an adhesive layer 231 is first coated on the surface layer 22, as shown in FIG. 4. The material of the adhesive layer 231 may be pressure sensitive adhesive, moisture-curing resin, one-component resin or two-component resin. Then, the adhesive layer 231 is dried. Finally, a PU wet foamed layer 232 is formed on the adhesive layer 231 so as to form the base layer 23, as shown in FIG. 5.

Referring to FIG. 6, a thermo-formable resin layer 24 is formed on the base layer 23. The thermo-formable resin layer 24 includes polyol. In the embodiment, the thermo-formable resin layer 24 is formed by coating, and further includes isocyanate. In the embodiment, the polyol is polycarbonate. In the embodiment, the method further comprises a step of drying the thermo-formable resin layer 24.

Referring to FIG. 7, a PU medium layer 25 is formed on the thermo-formable resin layer 24. In the embodiment, the PU medium layer 25 is formed by coating, and includes PU resin and powder of inorganic salt of CaCO₃, and the modulus of deformation of the PU resin is 20 to 150. In the embodiment, the method further comprises an aging step, which includes drying constantly over 24 hours in an oven without removing the release paper 21. Finally, referring to FIG. 8, the release paper 21 is removed so as to get a composite 2 with thermo-formability, and the composite 2 is turned upside down. After the release paper 21 is removed, the surface of the surface layer 22 has a texture corresponding to the texture of the release paper 21.

FIG. 8 shows the cross-sectional view of the composite with thermo-formability according to the first embodiment of the present invention. The composite 2 includes a PU medium layer 25, a thermo-formable resin layer 24, a base layer 23 and a surface layer 22. In the embodiment, the PU medium layer 25 includes PU resin and powder of inorganic salt of CaCO₃, and the modulus of deformation of the PU resin is 20 to 150. The thermo-formable resin layer 24 is disposed on the PU medium layer 25, and includes polyol. In the embodiment, the thermo-formable resin layer 24 further includes isocyanate, and the polyol is polycarbonate. The base layer 23 is disposed on the thermo-formable resin layer 24. In the embodiment, the base layer 23 includes an adhesive layer 231 and a PU wet foamed layer 232. The material of the adhesive layer 231 may be pressure sensitive adhesive, moisture-curing resin, one-component resin or two-component resin. The PU wet foamed layer 232 is adhered to the surface layer 22 by the adhesive layer 231. The surface layer 22 is disposed on the base layer 23. In the embodiment, the surface of the surface layer 22 has a texture, and includes PU resin, resistant and colorant. The resistant includes silicon so as to increase the abrasion resistance, and the colorant increases the UV resistance and the solvent resistance.

In the embodiment, the thickness of the PU resin layer 25 is 0.01 to 0.15 mm, the thickness of the thermo-formable resin layer 24 is 0.10 to 0.20 mm, the thickness of the PU wet foamed layer 232 is 0.20 to 0.45 mm, the thickness of the adhesive layer 231 is 0.01 to 0.15 mm, the thickness of the surface layer 22 is 0.01 to 0.05 mm, and the total thickness of the composite 2 is 0.33 to 1.00 mm.

FIGS. 9 to 14 show the cross-sectional views of the method for making a composite with thermo-formability according to the second embodiment of the present invention. First, referring to FIG. 9, a release paper 31 is provided. In the embodiment, the surface of the release paper 31 has a texture. Then, referring to FIG. 10, a surface layer 32 is formed on the release paper 31. In the embodiment, the surface layer 32 is formed by coating, and includes PU resin, resistant and colorant. The resistant includes silicon so as to increase the abrasion resistance, and the colorant increases the UV resistance and the solvent resistance. In the embodiment, the method further comprises a step of drying the surface layer 32. Then, referring to FIG. 11, a base layer 33 is formed on the surface layer 32. In the embodiment, a high-solid resin layer 331 is first coated on the surface layer 32, and the solid percentage of the high-solid resin layer 331 is more than 40%. Then, the high-solid resin layer 331 is dried so as to form the base layer 33.

Referring to FIG. 12, a thermo-formable resin layer 34 is formed on the base layer 33. The thermo-formable resin layer 34 includes polyol. In the embodiment, the thermo-formable resin layer 34 is formed by coating, and further includes isocyanate. In the embodiment, the polyol is polycarbonate. In the embodiment, the method further comprises a step of drying the thermo-formable resin layer 34.

Referring to FIG. 13, a PU medium layer 35 is formed on the thermo-formable resin layer 34. In the embodiment, the PU medium layer 35 is formed by coating, and includes PU resin and powder of inorganic salt of CaCO₃, and the modulus of deformation of the PU resin is 20 to 150. In the embodiment, the method further comprises an aging step, which includes drying constantly over 24 hours in an oven without removing the release paper 31. Finally, referring to FIG. 14, the release paper 31 is removed so as to get a composite 3 with thermo-formability, and the composite 3 is turned upside down. After the release paper 31 is removed, the surface of the surface layer 32 has a texture corresponding to the texture of the release paper 31.

FIG. 14 shows the cross-sectional view of the composite with thermo-formability according to the second embodiment of the present invention. The composite 3 includes a PU medium layer 35, a thermo-formable resin layer 34, a base layer 33 and a surface layer 32. In the embodiment, the PU medium layer 35 includes PU resin and powder of inorganic salt of CaCO₃, and the modulus of deformation of the PU resin is 20 to 150. The thermo-formable resin layer 34 is disposed on the PU medium layer 35, and includes polyol. In the embodiment, the thermo-formable resin layer 34 further includes isocyanate, and the polyol is polycarbonate. The base layer 33 is disposed on the thermo-formable resin layer 34. In the embodiment, the base layer 33 is a high-solid resin layer 331, and the solid percentage of the high-solid resin layer 331 is more than 40%. The surface layer 32 is disposed on the base layer 33. In the embodiment, the surface of the surface layer 32 has a texture, and includes PU resin, resistant and colorant. The resistant includes silicon so as to increase the abrasion resistance, and the colorant increases the UV resistance and the solvent resistance.

In the embodiment, the thickness of the PU resin layer 35 is 0.10 to 0.20 mm, the thickness of the thermo-formable resin layer 34 is 0.02 to 0.55 mm, the thickness of the high-solid resin layer 331 is 0.20 to 0.45 mm, the thickness of the surface layer 32 is 0.01 to 0.05 mm, and the total thickness of the composite 3 is 0.33 to 1.25 mm.

The composite 2, 3 of the present invention can be attached to a casing of a substrate (for example, an electrical device) so as to improve the tactile quality of the substrate. The method for attaching the composite 2, 3 comprises but is not limited to the following three methods.

First, the composite 2, 3 is adhered to the casing of the substrate directly. Second, the composite 2, 3 is adhered to the casing of the substrate after thermoforming. Third, the composite 2, 3 is thermoformed, and plastic is formed on the composite 2, 3 by injection molding so as to form the casing. Because the composite 2, 3 of the present invention has the thermo-formable resin layer 24, 34, the composite 2, 3 has good stability after thermoforming and avoids the usual problem of PC film 15 (FIG. 1) peeling off the composite 1.

FIGS. 15 to 17 show cross-sectional views of the method for making a casing with a texture on the surface thereof according to the first embodiment of the present invention. First, referring to FIG. 15, a composite is provided. The composite may be the composite 2 (FIG. 8) or the composite 3 (FIG. 14), and the composite 2 is illustrated hereinafter. The composite 2 includes a PU medium layer 25, a thermo-formable resin layer 24, a base layer 23 and a surface layer 22. In the embodiment, the PU medium layer 25 includes PU resin and powder of inorganic salt of CaCO₃, and the modulus of deformation of the PU resin is 20 to 150. The thermo-formable resin layer 24 is disposed on the PU medium layer 25, and includes polyol. In the embodiment, the thermo-formable resin layer 24 further includes isocyanate, and the polyol is polycarbonate. The base layer 23 is disposed on the thermo-formable resin layer 24. In the embodiment, the base layer 23 includes an adhesive layer 231 and a PU wet foamed layer 232. The PU wet foamed layer 232 is adhered to the surface layer 22 by the adhesive layer 231. The surface layer 22 is disposed on the base layer 23, and the surface of the surface layer 22 has a texture. In the embodiment, the surface layer 22 includes PU resin, resistant and colorant. The resistant includes silicon so as to increase the abrasion resistance, and the colorant increases the UV resistance and the solvent resistance.

Then, the composite 2 is thermoformed into a 3D appearance by a mold 4, and the 3D appearance corresponds to the shape of a casing 5 (FIG. 16). In the embodiment, the mold 4 includes a male mold 41 and a female mold 42. Referring to FIG. 16 again, a casing 5 is provided. Finally, referring to FIG. 17, the PU medium layer 25 is adhered to the surface of the casing 5, so that the composite 2 is adhered to the casing 5.

FIGS. 18 to 20 show cross-sectional views of the method for making a composite with thermo-formability according to the second embodiment of the present invention. First, referring to FIG. 18, a composite is provided. The composite may be the composite 2 (FIG. 8) or the composite 3 (FIG. 14), and the composite 2 is illustrated hereinafter. The composite 2 includes a PU medium layer 25, a thermo-formable resin layer 24, a base layer 23 and a surface layer 22.

Then, referring to FIGS. 18 and 19, the composite 2 is thermoformed into a 3D appearance by a mold 6. In the embodiment, the mold 6 includes a male mold 61 and a female mold 62. After thermoforming, the composite 2 has an inner surface 26 and an outer surface 27, and the inner surface 26 defines an inner space 28. The inner surface 26 is the surface of the PU medium layer 25, and the outer surface 27 is the surface of the surface layer 22. Finally, referring to FIG. 20, an in-mold-decoration process occurs, that is, plastic is formed on the inner surface 26 of the inner space 28 by inject molding so as to form a casing 7.

In the embodiment, the composite 2 has good stability after thermoforming, and plastic can be injected into the composite 2, so the conventional PC film is unnecessary.

While several embodiments of the present invention have been illustrated and described, various modifications and improvements can be made by those skilled in the art. The embodiments of the present invention are therefore described in an illustrative but not restrictive sense. It is intended that the present invention should not be limited to the particular forms as illustrated, and that all modifications which maintain the spirit and scope of the present invention are within the scope defined in the appended claims. 

1. A method for making a composite with thermo-formability, comprising the steps of: (a) providing a release paper; (b) forming a surface layer on the release paper; (c) forming a base layer on the surface layer; (d) forming a thermo-formable resin layer that includes polyol on the base layer; (e) forming a PU medium layer on the thermo-formable resin layer; and (f) removing the release paper.
 2. The method as claimed in claim 1, wherein in Step (a), the surface of the release paper has a texture, in Step (b), the surface layer is formed by coating, the surface layer includes PU resin, resistant and colorant, the resistant includes silicon, in Step (d), the thermo-formable resin layer is formed by coating, the thermo-formable resin layer further includes isocyanate, the polyol is polycarbonate, and in Step (e), the PU medium layer is formed by coating, the PU medium layer includes PU resin and CaCO₃, and the modulus of deformation of the PU resin is 20 to
 150. 3. The method as claimed in claim 1, further comprising a step of drying the surface layer after Step (b), a step of drying the thermo-formable resin layer after Step (d), and an aging step, which includes drying constantly over 24 hours in an oven without removing the release paper, after Step (e).
 4. The method as claimed in claim 1, wherein Step (c) comprises the steps of: (c1) coating a high-solid resin layer on the surface layer, wherein the solid percentage of the high-solid resin layer is more than 40%; and (c2) drying the high-solid resin layer so as to form the base layer.
 5. The method as claimed in claim 1, wherein Step (c) comprises the steps of: (c1) coating an adhesive layer on the surface layer; (c2) drying the adhesive layer; and (c3) forming a PU wet foamed layer on the adhesive layer so as to form the base layer.
 6. A composite with thermo-formability, comprising: a PU medium layer; a thermo-formable resin layer, disposed on the PU medium layer, wherein the thermo-formable resin layer includes polyol; a base layer, disposed on the thermo-formable resin layer; and a surface layer, disposed on the base layer.
 7. The composite as claimed in claim 6, wherein the PU medium layer includes PU resin and CaCO₃, the modulus of deformation of the PU resin is 20 to 150, the thermo-formable resin layer further comprises isocyanate, the surface of the surface layer has a texture, the surface layer includes PU resin, resistant and colorant, the resistant includes silicon, and the polyol is polycarbonate.
 8. The composite as claimed in claim 6, wherein the base layer is a high-solid resin layer, and the solid percentage of the high-solid resin layer is more than 40%.
 9. The composite as claimed in claim 8, wherein the thickness of the PU resin layer is 0.10 to 0.20 mm, the thickness of the thermo-formable resin layer is 0.02 to 0.55 mm, the thickness of the high-solid resin layer is 0.20 to 0.45 mm, the thickness of the surface layer is 0.01 to 0.05 mm, and the total thickness of the composite is 0.33 to 1.25 mm.
 10. The composite as claimed in claim 6, wherein the base layer includes an adhesive layer and a PU wet foamed layer, and the PU wet foamed layer is adhered to the surface layer by the adhesive layer.
 11. The composite as claimed in claim 10, wherein the thickness of the PU resin layer is 0.01 to 0.15 mm, the thickness of the thermo-formable resin layer is 0.10 to 0.20 mm, the thickness of the PU wet foamed layer is 0.20 to 0.45 mm, the thickness of the adhesive layer is 0.01 to 0.15 mm, the thickness of the surface layer is 0.01 to 0.05 mm, and the total thickness of the composite is 0.33 to 1.00 mm.
 12. A method for making a casing with a texture on the surface thereof, comprising the steps of: (a) providing a composite that includes a PU medium layer, a thermo-formable resin layer, a base layer and a surface layer; the thermo-formable resin layer is disposed on the PU medium layer, the thermo-formable resin layer includes polyol, the base layer is disposed on the thermo-formable resin layer, the surface layer is disposed on the base layer, and the surface layer has a texture on the surface thereof; (b) thermoforming the composite into a 3D appearance by a mold; (c) providing a casing; and (d) adhering the composite to the casing.
 13. The method as claimed in claim 12, wherein in Step (a), the PU medium layer includes PU resin and CaCO₃, the modulus of deformation of the PU resin is 20 to 150, the thermo-formable resin layer further includes isocyanate, the surface layer includes PU resin, resistant and colorant, the resistant includes silicon, the polyol is polycarbonate, and in Step (b), the mold includes a male mold and a female mold.
 14. The method as claimed in claim 12, wherein in Step (a), the base layer is a high-solid resin layer, and the solid percentage of the high-solid resin layer is more than 40%.
 15. The method as claimed in claim 12, wherein in Step (a), the base layer includes an adhesive layer and a PU wet foamed layer, and the PU wet foamed layer is adhered to the surface layer by the adhesive layer. 